Spring deck and insulator for furniture

ABSTRACT

A spring deck and insulator for furniture consisting of a planar sheet having a continuous series of closely spaced parallel cross wires connected at their ends to flexible side strands and a series of flexible straps extending parallel to and spaced intermediate the side strands, each strap being secured to each of the cross wires at its point of intersection therewith, the sheet being adapted to be inserted with or without edge connections between a spring deck and padding layers of upholstered furniture for use as an insulator pad, or to be used as a spring deck by securing it in a rigid furniture frame by resilient fasteners extending from each of the side strands and from each end of each of the straps, to the frame.

llnited States Patent 1 Platt et a1.

SPRING DECK AND INSULATOR FOR FURNITURE Assignee: Flex-O-Lators, Inc.,Carthage, Mo.

Filed: Aug. 5, 1971 Appl. No.2 169,279

References Cited UNITED STATES PATENTS 3/1970 Arnold et al. ..5/3547/1965 Richardson et al. 10/1967 Cundiff ..5/l91 51 May 22, 19733,310,300 3/1967 Lawson ..297/4S2 Primary Examiner-Casmir A. NunbergAttorney-John A. Hamilton [5 7] ABSTRACT A spring deck and insulator forfurniture consisting of a planar sheet having a continuous series ofclosely spaced parallel cross wires connected at their ends to flexibleside strands and a series of flexible straps extending parallel to andspaced intermediate the side strands, each strap being secured to eachof the cross wires at its point of intersection therewith, the sheetbeing adapted to be inserted with or without edge connections between aspring deck and padding layers of upholstered furniture for use as aninsulator pad, or to be used as a spring deck by securing it in a rigidfumiture frame by resilient fasteners extending from each of the sidestrands and from each end of each of the straps, to the frame.

10 Claims, 8 Drawing Figures SPRING DECK AND INSULATOR FOR FURNITUREThis invention relates to new and useful improvements in furnitureaccessories, and has particular reference to a novel wire fabric sheetformed of resilient flexible strands which may be used, either as aspring deck for resiliently supporting mattresses, cushions, or otherpadding material in furniture, or as an insulator pad, insulator padscomprising sheets of flexible or pliable material intended for insertionbetween a base spring deck and the padding layers of upholsteredfurniture, with the purpose of better supporting the pad ding layers andpreventing said padding from working downwardly into the spaces withinand between the spring elements constituting the base spring deck.

A primary object of the present invention is the provision of a sheetfor the above purposes which is resiliently flexible, having substantialresistance to flexure transversely of its plane. In either applicationthereof, this resilient stiffness tends to prevent over-localizedyielding thereof when it is top-loaded in normal use,-or in other wordsto reduce hammocking thereof under load by spreading the deflection overa larger area thereof. Such hammocking is a common and wellknown causeof discomfort, particularly in edgesupported spring decks, such as arecommonly used in baby cribs, cots, and other low-cost beddingstructures. Even in the use of insulator pads, when the yieldcharacteristics are ordinarily determined primarily by the base springdeck rather than by the insulator pad, the use of a resiliently stiffinsulator pad can improve the yield characteristics by spreading theload, or permit the use of base spring decks in which the deck springelements are more widely spaced, and which is hence more cheaplymanufactured.

In the manufacture of a resiliently stiff sheet for these purposes it iseconomically desirable that it be a woven fabric of spring steel wiresor other strands, and that it include strands extending angularly or atright angles to each other, in order to maintain a generally uniformflexibility about any axis. The difficulties of connecting intersectingstrands of spring steel in such a manner that they are not bent orotherwise deformed to such an extent as to lose objectionably largedegrees of their resilience, and in which they are not welded orotherwise heated so as to lose their temper, are well known.Accordingly, another object of the present invention is the provision ofa novel attachment of intersecting spring steel strands which causesnone of these undesirable results.

Other objects are simplicity and economy of construction, and efficiencyand dependability of operation.

With these objects in view, as well as other objects which will appearin the course of the specification, reference will be had to theaccompanying drawing, wherein:

FIG. 1 is a top plan view of a rigid frame, having a wire fabric sheetembodying the present invention mounted operatively therein for use as aspring deck,

FIG. 2 is an enlarged fragmentary view similar to FIG. 1, showing acorner portion of the frame, and showing also a slight modification ofstructure,

FIG. 3 is a fragmentary sectional view taken on line III-III of FIG. 2,

FIG. 4 is an enlarged fragmentary sectional view taken on line IV-IV ofFIG. 2,

FIG. 5 is a fragmentary sectional view taken on line V-V of FIG. 4,

FIG. 6 is an enlarged fragmentary sectional view taken on line VI-VI ofFIG. 2,

FIG. 7 is an enlarged fragmentary sectional view taken on line VII-VIIof FIG. 2, and

FIG. 8 is an enlarged fragmentary sectional view taken on line VIII-VIIIof FIG. 2.

Like reference numerals apply to similar parts throughout the severalviews, and it will be seen in FIG. 1 that the resilient sheet formingthe central subject matter of the present invention, and which may beutilized either as a spring deck or as an insulator pad, is indicatedgenerally by the numeral 10, and includes a pair of generally parallelside strands 12, a series of cross wires 14 extending between said sidestrands at right angles thereto and secured at their ends to said sidestrands, and a series of steel straps 16 extending parallel to said sidestrands in spaced relation thereto and attached to said cross wires.Side strands 12 each have a core 18 consisting of a relatively heavyspring steel wire, said core being wrapped or covered by a sheath 20 ofsoft, indentable material such as twisted paper or the like. Said sidestrands are spaced apart the full width of the sheet.

Cross wires 14, which are of tempered spring steel, are disposed in acontinuous series extending in parallel, spaced apart relation betweenside strands 12, at right angles to said side strands, and each crosswire has its ends affixed respectively to the two side strands by beingwrapped tightly about the sheaths 20 thereof, in indenting relationthereto, and then twisted about itself in a knot 22, as best shown inFIG. 6. The sheaths 20 form a strong, anti-slip purchase for the crosswires, and also prevent the rubbing or grating wire noises which wouldotherwise occur during use. Straps 16 constitute thin planar strips ofspring steel and extend the full length of sheet 2 in parallel, spacedapart relation intemediate and parallel to side strands 12, overlyingcross wires 14. Each strap is secured to each cross wire at its point ofintersection therewith, in a manner best illustrated in FIGS. 4 and 5. Apair of parallel slits are cut longitudinally in the strap over eachwire, whereby to form a narrow band 24 of the strap therebetween. Saidband is centered with respect to the associated cross wire, and isseveral times as long as the diameter of the wire. Band 24 is thenoffset downwardly as shown by pressure thereon, and wire 14 insertedtransversely through the loop formed between said band and theremaining, undeflected portion of the strap at that lateral linethereof. Preferably, band 24 is depressed only sufficiently to permitthe insertion of the wire, so that when released, it will recoverelastically to a suffrcient degree to clamp the wire firmly in place.This type of connection has several advantages. It can be performedrapidly and efficiently on automatic machinery, as by feeding straps 16longitudinally past a work station at which the bands 24 for each wireare cut and depressed by rolling toothed wheels, and at which wires 14are successively inserted, the cutting teeth being notched to permit theinsertion of the wires. Also, side strands 12 may be fed concurrentlywith the straps, and cross wires 14 knotted thereabout at the same workstation. The connection involves no application of heat, and there hencecan be no loss of temper from this cause. Also, there is almost no lossof temper orresilience due to cold working or permanent deformation.

Cross wires 14 are of course not affected at all in this manner, andstraps 16, though slightly deformed, are not materially affected so longas bands 24 are sufficiently narrow relative to the total width of thestrap. The bands should be no wider than perhaps one quarter of thestrap width, as shown, and may actually be substantially narrower. Whilethe connection is quite adequately secure for the purposes intended, itwill be seen also that if bands 24 are sufficiently narrow, theconnection will permit a degree of relative pivoting of the wires andthe straps, in the plane of the sheet. Strains tending to produce thistype of movement occur continuously in normal usage, and thepivotability provided tends to remove localized stresses from the wiresand straps at the connections.

If the sheet 2 is to be used as a spring deck in its own right, it mustbe resiliently supported in a furniture frame. Such a frame, which asshown may constitute the frame of a baby crib, cot, or other bed, isindicated generally at 26, and consists of side rails 28 and 30 and endrails 32 and 34. Said side and end rails are formed of angle iron andare rigidly interconnected to form an open rectangular frame somewhatlarger in both dimensions than sheet 2. Sheet 2 is disposed centrally insaid frame, and side strands 12 thereof are each connected to theadjacent side frame rail by a series of helical springs 36 extending atright angles to said side strands. Each spring is hooked at one endaround said side strand, and at its opposite end into a hole 38 punchedtherefor in the side frame rail. Said springs are installed under adegree of resilient extension. The stiff core wires 18 of the sidestrands permit a smaller number of springs 36 to be used, spaced atgreater intervals along the side strands, since stresses applied to anumber of cross wires 14 in use are transmitted thereby to a singlespring. Each end of each strap 16 is also connected to frame 26 by atensioned helical spring 40, each of said springs being hooked at oneend in a hole 42 formed therefor in the end portion of its related strap16, and at its opposite end in a hole 44 formed therefor in the adjacentend frame rail 32 or 34. Also, each end of each side strand 12 may beattached to the end frame rails by a helical spring 46 as shown in FIGS.2 and 7, one end of said spring being hooked in an eye 48 formed byextending and twisting the core wire 18 of the side strand, and theopposite end of said spring being hooked in a hole 50 formed therefor inthe adjacent frame end rail. While the use of both a side spring 36 andan end spring 46 at each corner of sheet 2 does improve the cornersupport of the sheet, the extension and twisting of core wires 18 toform eyes 48 does represent a time-consuming and hence expensiveoperation, and in some cases springs 46 may be dispensed with, asindicated in FIG. 1. Also, if desired, end springs 46 could be used andthe endmost side springs 36 at each side of the frame dispensed with. Insome cases it may be desirable to attach one edge of the sheet, notablythe forward edge in seating structures, directly to the frame, as bystapling, rather than by springs. The present structure is admirablysuited for this type of connection.

Of course, if sheet 2 is to be used simply as a padding insulator pad,the edge springs 36, 40, and 46 are not used, and the sheet 2 is simplylaid over a base spring deck, either attaching said sheet to the deck,as by clipping it to the deck, or not, and the padding material appliedthereover.

In use either as a spring deck or as an insulator pad, the close spacing(about one inch) of cross wires 14 provides sufficiently continuoussupport for any mattress, cushion, or other padding material appliedthereover to prevent said padding material from working downwardlytherebetween. Straps 16, by their width, also assist in providing thissupport. Also, the resilient resistance to flexure of sheet 2,transversely to its plane, creates a degree of stiffness which tends tospread the downward deflection thereof caused by localized loading overa larger area thereof. This reduces the previously discussed hammockingeffect, and the discomfort normally resulting therefrom, by causing ahigher proportion of the total yield of sheet 2 to be the result ofyielding of edge springs 36, 40, and 46, rather than virtually entirelyfrom the bowing or hammocking of the sheet itself. The reduction ofhammocking by the resilient stiffness of the sheet is of courseparticularly important in the spring deck usage of the sheet. However,this stiffness is also important in the use of the sheet as an insulatorpad, since it permits the sheet to be applied, without loss of comfortor support, over a spring deck the coil springs or other spring elementsof which are more widely spaced apart, thus rendering the totalstructure more economical. In the insulator pad usage, however, the corewires 18 of side strands 12 serve no particular function, and could bedispensed with.

The connections as shown between cross wires 14 and straps 16 are quiteimportant. They may be performed rapidly and economically by automaticmachinery. They involve no significant deformation or application ofheat to the spring members, so that they cause substantially no loss ofresilience or spring temper. The straps maintain uniform spacing of thecross wires, which is of course essential to the padding supportfunction of the sheet. The relative pivotal movement of the wires andstraps, in the plane of the sheet, as permitted by the connectionsshown, is also important. Such movement tends to occur every time thesheet is deflected to a non-planar form by loading thereof, and if notpermitted, would cause localized stresses at the connections,particularly in wires 14, which could cause early failure and breakagethereof.

While we have shown and described certain specific embodiments of ourinvention, it will be readily apparent that many minor changes ofstructure and operation could be made without departing from the spiritof the invention.

What we claim as new and desire to protect by Letters Patent is:

l. A device adapted to be used either as a spring deck or as aninsulator pad, comprising a generally planar sheet inelastic in its ownplane but possessing substantial resilient resistance to flexuretransversely of its plane about any line thereof in any direction.

2. A device as recited in claim I intended specifically for use as aspring deck, in which is additionally included a series of elongated,longitudinally extensible connectors connected to said sheet at spacedintervals around any desired portions of the periphery thereof andextending outwardly therefrom, said connectors being adapted to beresiliently extended and connected at their outer ends to a rigidfurniture frame.

3. A device as recited in claim 1 wherein said sheet comprises:

a. a pair of side strands disposed in generally parallel relation,

b. a continuous series of resilient cross wires extend ing in parallelrelation between and secured at their ends to said side strands, and

c. resilient straps extending parallel to and intermediate said sidestrands, and' intersecting said cross wires, each of said straps beingattached to each of said cross wires at its point of intersectiontherewith.

4. A device as recited in claim 3 intended specifically for use as aspring deck, with the addition of a series of elongated, longitudinallyextensible connectors connectable to said side strands in spacedrelation therealong, and to each end of each of said straps, andextending outwardly from said sheet, said connectors being adapted to beresiliently extended and connected at their outer ends to a rigidfurniture frame.

5. A device as recited in claim 4, wherein said side strands are alsoresilient, whereby longitudinal stresses on a plurality of said crosswires are transmitted by said side strands to each of said connectors.

6. A device as recited in claim 5 wherein each of said side strandsincludes a resilient wire having an eye formed at each end thereof, andwith the addition of connectors connectable to each end of each of saidside strands and adapted to be resiliently extended for connection attheir outer ends to said rigid furniture frame.

7. A device as recited in claim 3 wherein each of said side strandsconstitutes a spring wire core having a sheath of soft, indentablematerial applied thereto, each of said cross wires being twisted tightlyabout the sheath of each of said side strands and then about itself.

8. A device as recited in claim 3 wherein each of said cross wires isattached to each of said straps by means permitting a degree of relativepivotal movement therebetween, in the plane of said sheet.

9. A device as recited in claim 3 wherein a narrow longitudinal band ofeach said straps, intermediate the transverse edges thereof andtransversely spanning each cross wire intersecting said strap, is offsettransversely from the plane of said strap to form a loop in conjunctionwith the non-offset portion of said strap, said cross wire extendingthrough said loop.

10. A device as recited in claim 9 wherein said loop is elasticallycontracted by the resilience of said strap, whereby said wire is grippedin said loop.

1. A device adapted to be used either as a spring deck or as aninsulator pad, comprising a generally planar sheet inelastic in its ownplane but possessing substantial resilient resistance to flexuretransversely of its plane about any line thereof in any direction.
 2. Adevice as recited in claim 1 intended specifically for use as a springdeck, in which is additionally included a series of elongated,longitudinally extensible connectors connected to said sheet at spacedintervals around any desired portions of the periphery thereof andextending outwardly therefrom, said connectors being adapted to beresiliently extended and connected at their outer ends to a rigidfurniture frame.
 3. A device as recited in claim 1 wherein said sheetcomprises: a. a pair of side strands disposed in generally parallelrelation, b. a continuous series of resilient cross wires extending inparallel relation between and secured at their ends to said sidestrands, and c. resilient straps extending parallel to and intermediatesaid side strands, and intersecting said cross wires, each of saidstraps being attached to each of said cross wires at its point ofintersection therewith.
 4. A device as recited in claim 3 intendedspecifically for use as a spring deck, with the addition of a series ofelongated, longitudinally extensible connectors connectable to said sidestrands in spaced relation therealong, and to each end of each of saidstraps, and extending outwardly from said sheet, said connectors beingadapted to be resiliently extended and connected at their oUter ends toa rigid furniture frame.
 5. A device as recited in claim 4, wherein saidside strands are also resilient, whereby longitudinal stresses on aplurality of said cross wires are transmitted by said side strands toeach of said connectors.
 6. A device as recited in claim 5 wherein eachof said side strands includes a resilient wire having an eye formed ateach end thereof, and with the addition of connectors connectable toeach end of each of said side strands and adapted to be resilientlyextended for connection at their outer ends to said rigid furnitureframe.
 7. A device as recited in claim 3 wherein each of said sidestrands constitutes a spring wire core having a sheath of soft,indentable material applied thereto, each of said cross wires beingtwisted tightly about the sheath of each of said side strands and thenabout itself.
 8. A device as recited in claim 3 wherein each of saidcross wires is attached to each of said straps by means permitting adegree of relative pivotal movement therebetween, in the plane of saidsheet.
 9. A device as recited in claim 3 wherein a narrow longitudinalband of each said straps, intermediate the transverse edges thereof andtransversely spanning each cross wire intersecting said strap, is offsettransversely from the plane of said strap to form a loop in conjunctionwith the non-offset portion of said strap, said cross wire extendingthrough said loop.
 10. A device as recited in claim 9 wherein said loopis elastically contracted by the resilience of said strap, whereby saidwire is gripped in said loop.